Wacker Neuson PT 6L, Operator'S Manual

Page 1: ...0154629en 008 0810 0 1 5 4 6 2 9 E N Operator s Manual Pump PT 6L ...

Page 2: ... distribution not authorized by Wacker Neuson Corporation represents an infringement of valid copyrights Violators will be prosecuted Trademarks All trademarks referenced in this manual are the property of their respective owners Manufacturer Wacker Neuson Corporation N92W15000 Anthony Avenue Menomonee Falls WI 53051 U S A Tel 262 255 0500 Fax 262 255 0550 Tel 800 770 0957 www wackerneuson com Ori...

Page 3: ... manufactured up until the time of publication Wacker Neuson Corporation reserves the right to change any portion of this information without notice CALIFORNIA Proposition 65 Warning Engine exhaust some of its constituents and certain vehicle components contain or emit chemicals known to the State of California to cause cancer and birth defects or other reproductive harm Laws pertaining to spark a...

Page 4: ...parts attachments or modifications may have the following consequences Serious injury hazards to the operator and persons in the work area Permanent damage to the machine which will not be covered under warranty Contact your Wacker Neuson dealer immediately if you have questions about approved or unapproved parts attachments or modifications ...

Page 5: ...ing Safety 14 1 7 Reporting Trailer Safety Defects 14 2 Labels 16 2 1 Label Locations 16 2 2 Label Meanings 17 3 Lifting and Transporting 20 3 1 Lifting the Machine 20 3 2 Tires 21 3 3 Wheels and Lug Nuts 21 3 4 Tongue Jack 21 3 5 Safety Chains 22 3 6 Lights 23 4 Operation 24 4 1 Preparing the Machine for First Use 24 4 2 Control Component Descriptions 24 4 3 Control Component Locations 25 4 4 Rec...

Page 6: ...ngine Fuel Delivery System Maintenance 37 5 3 Servicing the Air Cleaner 37 5 4 Maintaining the Fuel Filter 38 5 5 Priming the Fuel System 38 5 6 Lubrication 39 5 7 Engine Oil 40 5 8 Valve Clearances 40 5 9 Fan Belt 41 5 10 Pump Housing Mounting Bolts 42 5 11 Mechanical Seal Lubrication 43 5 12 Bearing Housing Lubrication 44 5 13 Impeller Inspection 44 5 14 Engine Cooling Fins 47 5 15 Battery 47 5 ...

Page 7: ... 1 Trailer Wiring 53 7 2 Electrical Wiring 0007174 Rev 120 0007175 Rev 123 54 7 3 Electrical Wiring Components 0007174 Rev 120 0007175 Rev 123 55 7 4 Electrical Wiring 0007174 Rev 119 0007175 Rev 122 56 7 5 Electrical Wiring Components 0007174 Rev 119 0007175 Rev 122 57 ...

Page 8: ...8 wc_bo0154629en_008TOC fm Table of Contents PT 6L ...

Page 9: ...ersonal hazards f Obey all safety messages that follow this symbol DANGER DANGER indicates a hazardous situation which if not avoided will result in death or serious injury f To avoid death or serious injury from this type of hazard obey all safety mes sages that follow this signal word WARNING WARNING indicates a hazardous situation which if not avoided could result in death or serious injury f T...

Page 10: ...lf with the location and proper use of all controls Inexperienced operators should receive instruction from someone familiar with the machine before being allowed to operate it Operator qualifications Only trained personnel are permitted to start operate and shut down the machine They also must meet the following qualifications have received instruction on how to properly use the machine are famil...

Page 11: ...the pump with the cover off The rotating impeller inside the pump can cut or sever objects caught in it 1 3 8 NEVER block or restrict flow from the inlet line or the discharge line Remove kinks from the discharge line before starting the pump Operation with a blocked inlet line or discharge line can cause water inside the pump to overheat 1 3 9 NEVER reach into or insert anything into the pump whi...

Page 12: ... the machine away from the spill and wipe the machine dry before starting Refueling safety When refueling the engine Clean up any spilled fuel immediately Refill the fuel tank in a well ventilated area WARNING Internal combustion engines present special hazards during operation and fueling Failure to follow the warnings and safety standards could result in severe injury or death f Read and follow ...

Page 13: ...th side shields Hearing protection Safety toed footwear In addition before servicing or maintaining the machine Tie back long hair Remove all jewelry including rings 1 5 1 Do not attempt to clean or service the machine while it is running Rotating parts can cause severe injury 1 5 2 Do not use gasoline or other types of fuels or flammable solvents to clean parts especially in enclosed areas Fumes ...

Page 14: ...railer using defective parts 1 6 3 ALWAYS make sure the coupling is securely fastened to the vehicle 1 6 4 ALWAYS check the tires on the trailer for tread wear inflation and condition Replace worn tires 1 6 5 ALWAYS connect the safety chains 1 6 6 ALWAYS connect the breakaway cable safety hook to the bumper or rear of the vehicle DO NOT attach it to the hitch 1 6 7 ALWAYS test the surge brakes on ...

Page 15: ...TSA cannot become involved in individual problems between you your dealer or Wacker Neuson Corporation To contact NHTSA you may either contact the Auto Safety Hotline toll free at 1 800 424 9393 or 366 0129 in Washington DC area www nhtsa com or write to NHTSA U S Department of Transportation 400 7th Street SW NSA 11 Washington DC 20590 You can also obtain other information about motor vehicle saf...

Page 16: ...Labels PT 6L 16 wc_si000523gb fm 2 Labels 2 1 Label Locations wc_gr001145 1 13 3 7 6 3 8 14 10 9 5 6 4 12 11 2 ...

Page 17: ...he Operator s Manual No sparks flames or burning objects near the machine Stop the engine before refueling CAUTION Use only clean filtered diesel fuel 2 Storage location of Operator s Manual The Operator s Manual should be stored on the machine 3 CAUTION Read and understand the supplied Operator s Manual before operating this machine Failure to do so increases the risk of injury to yourself and ot...

Page 18: ...iler 9 This machine may be covered by one or more patents 10 A nameplate listing the model number item number revision number and serial number is attached to each unit Please record the infor mation found on this nameplate so it will be available should the nameplate become lost or damaged When ordering parts or requesting service information you will always be asked to specify the model number i...

Page 19: ...PT 6L Labels wc_si000523gb fm 19 13 Low sulfur fuel or ultra low sulfur fuel only 14 Transport position of the jack 15 NOTICE Add oil to air cleaner before starting engine ...

Page 20: ...e must have capacity of at least 1090 Kg 2400 lbs Only use steel ropes or chains for hoisting The rope or chain must have the suitable specified lifting capacity of 1090 Kg 2400 lbs Do not use improvised ropes or chains Never use any other part of the PT6 Pump to lift the machine as severe damage may occur Do not stand under or get onto the machine while it is being hoisted or moved WARNING CAUTIO...

Page 21: ...eel and tire 3 3 Wheels and Lug Nuts Loose or missing lug nuts can cause you to lose a wheel Keep all lug nuts tight Before each trip check for loose or missing lug nuts When replacing lug nuts make sure the replacement nut matches the original nut exactly While the threads of the nut may match the nut may be a size that does not hold the wheel securely against the hub even when fully tightened To...

Page 22: ...e each trip Chains should be attached in a crossing pattern under the trailer tongue The chains will prevent the trailer tongue from dropping to the ground if the trailer separates from the hitch Rig the chains as tight as possible with just enough slack to permit tight turns If a chain must be replaced do not substitute a lighter weight chain This trailer must be equipped with two chains each wit...

Page 23: ...s are working before towing the trailer State and federal regulations require that all types of trailers be equipped with tail stop and turn lights e and side marker lights f A special wiring harness g for connecting the trailer lights to the lighting system of the tow vehicle is supplied with the trailer WARNING wc_gr003182 e f g ...

Page 24: ...ent parts not already attached 4 1 5 Add fluids as needed and applicable including fuel engine oil and battery acid 4 1 6 Move the machine to its operating location 4 2 Control Component Descriptions See Graphic wc_gr003183 Ref Description Ref Description 1 Engine oil dipstick 14 Engine oil filter 2 Fuel filter 15 Battery box 3 Manual fuel pump lever 16 Trailer hitch 4 Engine oil drain plug 17 Jac...

Page 25: ...PT 6L Operation wc_tx001597gb fm 25 4 3 Control Component Locations wc_gr003183 18 17 15 16 7 8 9 6 26 23 22 21 20 19 25 12 11 13 10 14 24 1 2 4 5 3 ...

Page 26: ...166 4 6 1 Check the bearing seal housing f for proper oil level Also check the oil for water contamination Do not operate the pump if contamination is found 4 6 2 Position the pump as near to the water as possible on a firm flat surface Keep the pump level 4 6 3 Lower the rear stabilizers a until they contact the ground Lock the stabilizers in position with the pins 4 6 4 Crank down the jack stand...

Page 27: ...1 Loosen the throttle lever knob c and set the engine throttle d to high speed Tighten the throttle lever knob 4 7 2 Open the cover on the battery box a and turn and hold the ignition key b to the ON position until the glow plug light on the control panel goes out Then turn the ignition key to the START position Release the key after the engine starts It will spring back into the ON position Note ...

Page 28: ...al housing The mechanical seal could overheat and be damaged Adjusting Pump Flow Pump flow can be set by adjusting the speed of the engine 4 7 1 To set the engine speed loosen the throttle lever knob c and adjust the throttle lever d 4 7 2 Tighten the throttle lever knob to hold the throttle lever in place while the pump is operating When priming the pump set the throttle lever at full speed until...

Page 29: ...s de energized the engine stops If the engine stops unexpectedly and the circuit breaker trips it is a sign of a problem with the fan belt Check the fan belt and replace it if necessary Reset the circuit breaker before resuming use of the pump If the engine stops unexpectedly without the circuit breaker tripping check the amount of oil in the engine crankcase Fill the engine crankcase with oil as ...

Page 30: ...ses to the suction and discharge ports as well as to connect two hose lengths together 4 13 Hose Clamps Suction Hose to Inlet Port Coupling At least two T bolt clamps are recommended for connection of the suction hose to the pump inlet Index clamps at 90 intervals for best seal Add additional clamps if the pump has trouble priming Note The smallest air leak on the suction side of the pump will pre...

Page 31: ...direct water flow in any direction To rotate the elbow 4 15 1 Remove the locknuts b which hold the port to the pump housing 4 15 2 Lift the port off the studs and position it as desired Always check the gasket and replace it if it is damaged 4 15 3 Tighten the locknuts evenly Torque them to 160 Nm 118 ft lbs wc_gr001184 a b ...

Page 32: ...inspect the pump interior To remove the impeller cover and elbow 4 16 1 Turn the inner star wheel d in until it is seated tightly against the impeller cover 4 16 2 Turn the outer star wheel e in until the cover is pulled out of the housing 4 16 3 When the impeller cover is free of the housing rotate the clamp f counterclockwise and pull the impeller cover from the housing To install the impeller 4...

Page 33: ...PT 6L Operation wc_tx001597gb fm 33 wc_gr003210 3 1 2 e g 3 1 2 d a b c f ...

Page 34: ...he tongue are secure To hitch the trailer 4 17 1 Back your vehicle as close as possible to the trailer It is easier and safer to back the tow vehicle under the trailer than to pull the trailer to the vehicle 4 17 2 Check that the coupler locking device h is released 4 17 3 Raise the trailer coupler using the tongue jack d to a height just above the ball on the hitch Carefully position the vehicle ...

Page 35: ...d and licensed by the State Department of Transportation Before towing be sure to check licensing requirements Always refer to the applicable Department of Transportation regulations before towing 4 18 Emergency Shutdown Procedure If a breakdown accident occurs while the machine is operating follow the procedure below 4 18 1 Stop the engine 4 18 2 Turn off the fuel supply 4 18 3 Remove the obstruc...

Page 36: ...eck engine oil Fill to correct level 3 Clean air cleaner 3 Check condition and tension on fan belt Change oil in engine crankcase Change engine oil filter Change fuel filter Clean engine cooling fins Check valve clearance Tighten fittings and clean injectors Replace fan belt Machine Daily before starting Every 100 hrs Every 250 hrs Every 500 hrs Check external hardware 3 Open pump housing cover an...

Page 37: ...several times during the day Change the oil if it appears thick or gritty Clean the air cleaner often Keep the oil bowl filled with clean oil up to level mark a NOTICE NEVER run the engine without oil in the air cleaner Severe engine damage will result To clean the air cleaner 5 3 1 Release the snap clips b and remove the oil bowl c 5 3 2 Remove the filter element d from the oil bowl Be careful no...

Page 38: ...letely dry it will be necessary to prime the fuel system To prime fuel system 5 5 1 Remove the small plug from the top of the water separator and prefill the element with clean diesel fuel 5 5 2 Loosen the bleed screw a on the fuel filter and pump the manual lever on the fuel pump b until fuel flows freely from the screw hole Tighten the bleed screw 5 5 3 Loosen the bleed screw c starting with the...

Page 39: ... the oil level is at the top mark Add oil through the oil filler cap a on top of engine checking occasionally with dipstick DO NOT overfill Suggested oil grades Use only diesel engine oil API service rating CD or equivalent ENGINE OIL VISCOSITY GRADE AMBIENT TEMPERATURE Ambient Temperature Multi grade 25ºC 13ºF 15ºC 5ºF 20ºC 4ºF 15ºC 59ºF 30ºC 86ºF 0ºC 32ºF SAE 10W 30 SAE 15W 40 20W 40 SAE 5W 20 w...

Page 40: ...of this liquid properly 5 7 2 Install the drain plug 5 7 3 Remove the oil filler cap a and fill the engine crankcase with the recommended oil Oil Capacity 5 liters 5 qts SAE15W40 CD rated 5 7 4 Install the oil filler cap 5 8 Valve Clearances See graphic wc_gr000476 Check and adjust the valve clearance every 500 hours Set the clearance when the engine is cold 5 8 1 Remove the rocker arm cover and c...

Page 41: ...d a and check the fan belt b for cracks or splitting 5 9 2 To tighten the fan belt add or remove spacers c located between the fan pulley halves d Spacers are 0 5 1 0 2 0 mm 0 017 0 034 0 068 in thick 5 9 3 To check fan belt tension press the fan belt halfway between belt pulleys with a 10 kg 22 lb load or strong thumb pressure The fan belt should deflect 1 cm 3 8 in wc_gr001190 a b d c ...

Page 42: ...using Mounting Bolts See graphic wc_gr003178 Tighten the mounting bolts a on the pump housing after the first 50 hours of operation Inspect the bolts periodically thereafter and tighten when required Torque the bolts to 330 Nm 243 ft lbs wc_gr003178 a ...

Page 43: ...anical seal however if water contamination is heavy and oil feels watered down inspect the mechanical seal for signs of wear or damage To check the oil level 5 11 1 Remove the plastic fill plug a from the top of the bearing housing The oil level should touch the base of the plug opening Add oil as required To change the oil 5 11 2 Remove the drain plug c from the bottom of the bearing housing 5 11...

Page 44: ...the insert 5 13 1 Shut down the machine DO NOT reach into or insert anything into the pump while the engine is running DO NOT run the pump with the impeller cover removed 5 13 2 Open the bottom drain cover and drain the pump 5 13 3 Remove the suction flange a and the flapper gasket b from the front of the pump Impeller edges can become extremely sharp use care when working on the pump to reduce th...

Page 45: ...eller cover Add shims as required and recheck the clearance gap After the proper shimming has been determined use a high strength threadlocking compound on the screws and secure the shims and insert to the impeller cover Torque the screws to 26 Nm 19 ft lbs 5 13 7 Reinstall the suction flange and the flapper gasket ...

Page 46: ...Maintenance PT 6L 46 wc_tx001598gb fm wc_gr003206 a b g c d d e e f g g e f g 0 15 0 75 mm 0 005 0 025 in ...

Page 47: ...eplace the inspection cover before starting the engine 5 15 Battery See Graphic wc_gr003177 The battery a supplied on this machine is a heavy duty lead acid battery rated at 12V 160 Ah BCI group 31 Check the level of the electrolyte in the battery periodically and add distilled water as required to keep the electrolyte at the correct level Keep the battery terminals clean and tighten them as requi...

Page 48: ...faulty Engine is hard to start Dirt or debris inside pump housing blocking move ment of impeller Battery charge low Engine faulty Engine starts but pump does not take in water Pump housing not filled with water Strainer on suction hose plugged Suction hose damaged Air leak above water line Air leak at suction port Pump too high above water line Engine speed too low Debris collecting in pump housin...

Page 49: ...hly clean the exterior of the pump and engine Visually inspect the machine for signs of damage or loose bolts 5 17 5 Remove the covers and clean the pump interior Wipe or spray all interior surfaces with a rust inhibiting oil 5 17 6 Change the oil in the seal and bearing housings 5 17 7 Replace the covers Seal the suction and discharge openings with tape 5 17 8 Remove the battery from the machine ...

Page 50: ...gine type Three cylinder 4 cycle air cooled diesel engine Engine make Lombardini Engine model 11LD625 3 Tier 4 Max rated power rated speed kW Hp 22 30 2500 rpm Alternator Amp 14 Operating speed rpm 2500 100 Engine speed idle rpm 1500 100 Valve clearance cold intake exhaust mm in 0 15 0 006 0 20 0 007 Air cleaner type Oil Bath Do not use oil lighter than 20W Battery V size 12V 31 Fuel type No 2 Die...

Page 51: ...tion discharge dia mm in 150 6 Max solid size mm in 50 2 Item No PT 6LT 0007175 PT 6LS 0007174 Lubrication Engine type qty SAE 15W40 CD Rated 5 0 L 5 qts Pump seal housing type qty SAE 15W40 800ml 27oz Pump bearing housing type qty SAE 15W40 470ml 16oz Item No PT 6LT 0007175 Trailer Power take off type Direct Drive with Flex Coupling Trailer tounge weight kg lbs 75 165 Gross vehicle weight Rating ...

Page 52: ...Technical Data PT 6L 52 wc_td000099gb fm 6 5 Dimensions wc_gr001154 ...

Page 53: ...hematics wc_tx001596gb fm 53 7 Schematics 7 1 Trailer Wiring Wire Colors B Black R Red Y Yellow Or Orange G Green T Tan Br Brown Pr Purple L Blue V Violet Cl Clear Sh Shield P Pink W White Gr Gray LL Light blue ...

Page 54: ... wc_gr007759 R R B RWB L W Br W Br L Br B B R L B W Br Y R Br L Gr W B Y G B B Y W B R Y Br L L Br P G W G L R Or R R G W R V B W R G Or Pr W W Y Y Y Y Y R B B R L L Y Y P B B L V B G Y B P B P B 50 30 15 54 86 85 30 87 1 3 4 5 6 7 8 25 26 9 10 11 12 13 22 21 14 23 23 15 16 17 18 24 19 20 2 ...

Page 55: ... 5 Throttle solenoid 18 Voltage regulator 6 Hour meter 19 Low oil pressure switch N O 7 Control panel 20 Low oil pressure switch N C 8 Keyswitch 21 Diagnostic port 9 Glow plug relay 22 Cam RPM sensor 10 15A Fuse 23 Control solenoids 11 20A Circuit breaker 24 Engine alternator 12 Pump sensor 25 80A Fuse 13 Engine RPM sensor 26 Control panel harness Wire Colors B Black R Red Y Yellow Or Orange G Gre...

Page 56: ... 6L 56 wc_tx001596gb fm 7 4 Electrical Wiring 0007174 Rev 119 0007175 Rev 122 wc_gr003173 W Or Br G B L Y G B B Y W R Y L Br G V W W Y Y Y Y Y R B B R L L L G Y B 50 30 15 54 1 3 5 6 7 8 4 10 11 13 14 9 12 6 15 2 R ...

Page 57: ...gine harness 10 15A Fuse 3 Extension harness 11 20A Circuit breaker 4 Control panel harness 12 Engine alternator 5 Throttle solenoid 13 Battery 6 Hour meter 14 Starter solenoid 7 Control panel 15 Oil pressure failure sensor 8 Keyswitch Wire Colors B Black R Red Y Yellow Or Orange G Green T Tan Br Brown Pr Purple L Blue V Violet Cl Clear Sh Shield P Pink W White Gr Gray LL Light blue ...

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Page 72: ... 390 Wacker Neuson Corporation N92W15000 Anthony Ave Menomonee Falls WI 53051 Tel 262 255 0500 Fax 262 255 0550 Tel 800 770 0957 Wacker Neuson Limited Room 1701 03 1717 20 17 F Tower 1 Grand Century Place 193 Prince Edward Road West Mongkok Kowloon Hongkong Tel 852 3605 5360 Fax 852 2758 0032 ...